Replacement of a front brake hose on a 2024 Tesla Model X Long Range. The job requires bleeding the brake circuit afterward and using new copper sealing washers at the banjo fitting.

Warnings

Tools required

Parts

• Front brake hose (manufacturer-specified for 2024 Model X) × 1 — OEM Tesla front brake hose — verify side (LH/RH)
• Copper sealing washers for banjo bolt × 2 — OEM-spec copper crush washers, banjo bolt size

Fluids

• DOT 3 Brake Fluid (sealed, fresh container) — 1 qt

Preparation

1. Park on level ground, place in P, engage parking brake.
2. Exit ALL doors with key fob away from the vehicle. Wait at least 2 minutes for HV systems to fully de-energize, even on this non-HV job.
3. Disconnect the 12V low-voltage battery located in the frunk (similar position to Model S). Follow the access panel removal sequence in the owner documentation.
4. DO NOT touch, cut, or pierce ANY orange cable — these are high-voltage and lethal.
5. If at any point you encounter an orange cable, an HV component, or are unsure if a system is de-energized: STOP and consult a Tesla-certified technician.
6. Before disconnecting 12V, enable Jack Mode via Controls > Service > Jack Mode so the air suspension does not attempt to self-level during the lift.
7. Chock the rear wheels.
8. Loosen the front wheel lug nuts while the vehicle is still on the ground.
9. Lift the front of the vehicle at the manufacturer-specified lift points using approved pucks, and support on jack stands.
10. Remove the front wheel on the side being serviced.
11. Inspect the brake fluid reservoir level and top off if low; identify the affected hose routing from caliper to hard line.

Procedure

1. 1

   Pre-position fluid catch and protect surfaces
   Place a catch pan beneath the caliper. Cover any painted suspension or body components near the hose routing with rags to absorb DOT 3 fluid drips.
2. 2

   Minimize fluid loss (optional)
   Optionally clamp the flexible portion of the hose with a brake hose pinch-off tool to reduce fluid loss while disconnected. Do not clamp on hard line or fitting areas.
   ⚠Use only a tool designed for brake hoses. Standard locking pliers will damage the inner liner.
3. 3

   Disconnect the hard line from the hose
   Using a flare-nut wrench, loosen the hard brake line fitting at the upper end of the flexible hose. Counter-hold the hose hex to prevent twisting. Allow fluid to drain into the catch pan; cap or plug the hard line to keep contaminants out.
   ⚠Do not use an open-end wrench on brake line fittings — it will round the soft fitting.
4. 4

   Release the hose from the chassis bracket
   Remove the retaining clip securing the hose at the chassis/strut bracket. Inspect the clip for distortion and replace if bent. Free the hose end from the bracket.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
5. 5

   Disconnect the banjo fitting at the caliper
   Using the correct socket or wrench, remove the banjo bolt at the caliper. Capture the two copper washers (one on each side of the banjo fitting) and discard them — they must be replaced. Allow remaining fluid to drain.
   ⚠Never reuse copper sealing washers — they are crush washers and will leak if reused.
6. 6

   Remove old hose
   Withdraw the old hose, noting its routing path, any anti-rotation features, and clip orientations. Compare the new hose to the old to confirm correct part and side (LH vs RH).
7. 7

   Install new hose at the chassis bracket
   Route the new hose along the same path as the original. Seat the upper end into the chassis bracket and install the retaining clip fully. Confirm there is no twist along the hose length and that it does not contact suspension or steering components through full travel.
   ⚠A twisted brake hose will fail prematurely. Verify the hose lies in its natural orientation before final securement.
   Torque spec

   Brake Hose Bracket10 Nm (7 lb-ft)
8. 8

   Connect hard line to hose
   Hand-thread the hard line fitting into the upper end of the hose to avoid cross-threading, then snug with a flare-nut wrench. Counter-hold the hose hex while final-tightening. Torque to OEM specification — refer to Tesla Service Manual.
9. 9

   Install banjo fitting at the caliper
   Place a NEW copper washer on each side of the banjo fitting (one between the bolt head and fitting, one between the fitting and caliper body). Thread the banjo bolt by hand, then torque to specification.
   ⚠Both copper washers must be new. Do not stack old and new washers.
   Torque spec

   Brake Hose Banjo Bolt25 Nm (18 lb-ft)
10. 10

    Bleed the brake circuit
    Top off the master cylinder reservoir with fresh DOT 3 brake fluid. Bleed the affected caliper using a vacuum or pressure bleeder until clear, bubble-free fluid flows. Maintain reservoir level above MIN throughout. If brake fluid service interval is due (every 2 years per Tesla), bleed all four corners in the manufacturer-specified sequence.
    ⚠Never let the reservoir run dry — air ingestion will require a full system bleed and may require a Tesla diagnostic-tool-assisted ABS bleed.
    Torque spec

    Bleeder Screw14 Nm (10 lb-ft)
11. 11

    Leak check under pressure
    With an assistant pressing the brake pedal firmly and holding, inspect the banjo fitting, hard-line connection, and bleeder for any seepage. Re-torque or re-seat as needed. Pedal should feel firm; if spongy, repeat bleeding.

Reassembly

1. Confirm bleeder screw is closed and torqued.
2. Wipe all fittings clean of brake fluid residue and inspect once more for leaks.
3. Top off master cylinder reservoir to MAX with fresh DOT 3 fluid and install the cap.
4. Reinstall the front wheel. Snug lug nuts in a star pattern.
5. Lower the vehicle to the ground.
6. Final-torque the wheel lug nuts in a star pattern.
7. Reconnect the 12V low-voltage battery in the frunk and reinstall any covers.
8. Close the frunk and exit Jack Mode (it will typically clear automatically once the suspension senses normal ride height; verify on the touchscreen).
9. Allow the air suspension to re-level before driving.

Verification

• With the vehicle running and brake pedal pumped, pedal should be firm and high — no sponginess.
• Confirm no brake fluid warning, ABS, or traction-control alerts appear on the touchscreen after a key cycle.
• Perform a low-speed (5–10 mph) brake test in a safe area; vehicle should stop straight with no pulling.
• At 25–35 mph, test moderate braking and confirm no ABS faults register.
• Inspect the banjo fitting and hard-line connection again after the test drive for any weeping.
• Through full steering lock left and right (with vehicle stationary), confirm the new hose does not contact tire, strut, or chassis at any angle.
• Log the brake fluid service date — Tesla recommends brake fluid replacement every 2 years regardless of mileage; if a partial bleed was performed, schedule a full flush at the next service interval.

More procedures for this vehicle